Modular wall construction

ABSTRACT

A wall structure comprising opposed panels supported on spaced apart vertical and horizontal channels mounted on support elements having differently configurated structures. The space between the opposed panels can remain open or be filled with a permanent building material. A variety of wall base constructions are provided, together with detachable frame assemblies for mounting doors and windows in the wall structure.

United States Patent Boice Apr. 2, 1974 [54] MODULAR WALL CONSTRUCTION3,475,870 11/1969 Birum 52/498 x [75] Inventor: G. Newton Bo ce,McKeesport Pa- 3,487,60l 1/1970 James 52/498 X Assigneer Structural yPrimary Examiner-Price c. Faw, Jr.

MCKBCSPOTL Attorney, Agent, or Firm-Christel & Bean [22] Filed: Jan. 3,1972 21 Appl. No.: 214,539 [571 ABSTRACT A wall structure comprisingopposed panels supported [52] U S CI 52/208 52/498 on spaced apartvertical and horizontal channels [51] E66) 1/04 mounted on supportelements having differently con- [58] Fieid 4 214 498 figuratedstructures. The space between the opposed panels can remain open or befilled with a permanent [56] References Cited building material. Avariety of wall base constructions are provided, together withdetachable frame assem- UNITED STATES PATENTS blies for mounting doorsand windows in the .wall 2,945,269 7/1960 Domen 52/498 X tructure2,983,001 5/l961 Gulda'geL. 52/208 3,090,085 5/1963 Brown 52/498 X 6Claims, 79 Drawing Figures ATENTEDAPR 21974 sum over 17 PATENTEBAPR21974 sum '06 or17 PATENIEDAPR 2:914

saw um 17 /IIII' FIG. 25

FIG. 27

PAIENTEDAPR em I 1800.489 sw ne or17 PATENTEHAPR 2 I974 saw 10 or 17PAIENTEDAPR 2 m4 SHEET '12UF17 FIG. 52

PAIENTEBAPR 2mm 3,800,489

' saw 150F17 BACKGROUND OF THE INVENTION This invention relatesgenerally to the construction art and, more particularly, to certain newand useful prefabricated, modular building constructions.

There presently exists a need for an inexpensive and practical form ofconstruction for residential housing, industrial, commercial andinstitutional buildings which can be mass produced and prefabricated offthe job site and readily installed at the construction site by unskilledlabor with maximum efficiency. In an effort to satisfy this need,various prefabricated modular building constructions have been proposedto provide structures which can be readily installed and which aredemountable and movable to shift walls, partitions and the like to otherpositions. While these prior known prefabricated constructions partiallysatisfy this need, they possess certain disadvantages. Some of theseconstructions include structural elements and components which span theentire width between walls to interfere with the placement of conduits,piping and the like. Sometimes, these known constructions do not provideadequate sound and heat control and are not capable of withstandingabnormally elevated temperatures, such as accompany a tire. Moreover,their versatility is often limited so that the various componentsconstituting the prefabricated construction can not be readilyinterchanged or combined to form a variety of arrangements.

SUMMARY OF THE INVENTION A primary object of the present invention is toobviate the above disadvantages by providing an improved modular wallconstruction, which can be quickly erected at the construction site byunskilled labor and which results in a strong and rigid construction,which is attractive in appearance, extremely versatile, relatively lowin costs, and which possesses desirable sound and heat controlqualities.

Another object of this invention is to provide a detachable, double wallpanel construction defining a substantially uninterrupted space thereinwhich can be left undisturbed for the placement of conduits and the liketherein, or which can be filled with concrete or other building materialin which case the detachable double wall panel construction serves as apouring form which can either be removed when the building material hasset to leave a permanent wall core remaining or which can remain intactto form with such core a composite permanent wall structure.

Another object of the present invention is to provide the foregoingdouble wall panel construction with a plurality of novel componentshaving a structural configuration whereby they can be used in pairs in anested relation or combined with each other to support the double wallpanel construction in any orientation as perimeter or partition walls.

Still another object of this invention is to provide the foregoing wallconstruction with various detachable frame assemblies for mountingdoors, windows and the like therein.

A further object of the present invention is to provide the foregoingdouble wall panel construction with supporting base structures in avariety of forms to enable erection of the former in any desiredarrangement.

The foregoing and other objects, advantages and characterizing featuresof this invention will become clearly apparent from the ensuing detaileddescription of illustrative embodiments thereof, taken together with theaccompanying drawings wherein like reference numerals denote like partsthroughout the various views.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary, perspectiveview of a modular, double wall structure, constructed in accordance withthe present invention;

FIG. 2 is a perspective view of a pair of spaced channel members of thisinvention;

FIG. 2A is a perspective view of a spacer plug adapted to be interposedbetween the channel members of FIG. 2;

FIG. 3 is a front elevational view, on a reduced scale, showing thechannel members of this invention arranged in a rectangular pattern;

FIG. 4 is a top plan view of a base channel member used with thisinvention;

FIG. 4A is a vertical sectional'view, illustrating one form of a flooredge member incorporated in this invention;

FIG. 5 is a fragmentary, perspective view illustrating basic structuralelements in an assembled relation for supporting the channel members ina spaced relation;

FIG. 6 is avertical sectional view, on an enlarged scale, showing thestructural elements of FIG. 5 in combination with the base channelmembers of FIG. 4, to gether with various plug elements;

FIG. 6A is a view similar to FIG. 6 showing the assembly of the lattersecured together by an anchor element;

FIG. 7 is a horizontal sectional view, on an enlarged scale, taken abouton line 7-7 of FIG. 5, illustrating connector clips for joining thechannel members together;

FIG. 8 is a fragmentary, vertical sectional view, showing base clipsused in conjunction with this invention;

FIG. 9 is a perspective view ofa foundation shoe element of thisinvention;

FIGS. 10 and 11 are perspective views of inner and outer cornerfoundation shoe elements used in this invention; I

FIG. 12 is a perspective view of a combination of differently configuredfoundation shoe elements arranged to form a T intersection;

FIG. 13 is a perspective view of a structural bridging plateincorporated in this invention;

FIGS. 14 and 15 are perspective views of inner and outer cornerstructural angles used in this invention;

FIGS. 16 and 17 are perspective views of inner and outer structuralrunner angles used in this invention;

FIG. 18 is a fragmentary, sectional perspective view, on an enlargedscale, taken about on line 18-48 of FIG. 4;

FIGS. 19 and 20 are fragmentary, perspective views, illustrating variousstages of the formation of one form of spacer used in conjunction withthis invention;

FIG. 21 is a fragmentary, longitudinal sectional view of one form of aspacer assembly of this invention;

FIG. 22 is an exploded view of a fastening assembly of this invention;

FIG. 23 is a longitudinal sectional view, partly in elevation, showingthe fastening assembly of this invention securing various structuralelements together;

FIG. 24 is a fragmentary, perspective view illustrating a cross bracemember assembled with one of the corner structural angles of thisinvention;

FIG. 25 is a horizontal sectional view illustrating some basiccomponents of this invention for supporting the channel members in aspaced relation;

FIG. 26 is a fragmentary, cross sectional view, partly in elevation,illustrating a tool implement of this invention used for detachinginterlocked structural members;

FIG. 27 is a fragmentary, sectional view illustrating a portion of afinished double wall construction incorporating the spaced wall panelmembers of this invention;

FIG. 28 is a fragmentary, sectional view illustrating a modified wallpanel member especially adapted for use as a form in the pouring of apliant building material;

FIG. 29 is a framentary, horizontal sectional view, on an enlargedscale, taken about on line 29-29 of FIG. 1, showing a cornerconstruction in accord with this invention;

FIG. 30 is a cross sectional view of a corner trim element used in thisinvention;

FIG. 31 is a cross sectional view of an inner corner filler block usedin conjunction with this invention;

FIG. 32 is a cross sectional view of a backing strip incorporated inthis invention;

FIG. 33 is a vertical sectional view, on an enlarged scale, taken abouton line 33-33 of FIG. 1, showing one form of a wall base construction ofthis invention;

FIG. 34 is a cross sectional view of one form ofa filler block employedin the wall base construction of FIG. 33, shown assembled with amodified form of base clip;

FIG. 35 is a view similar to FIG. 33, showing spaced panel memberssupported on the wall base construction thereof;

FIG. 36 is a cross sectional view of one form of a base edging memberutilized in the wall base construction of FIG. 35;

FIG. 37 is a cross sectional view of another form of a base edgingmember optionally used in the wall base construction of FIG. 35;

FIG. 37A is a cross sectional view of still another form of a baseedging member incorporating electrical connection means therein;

FIG. 38 is a cross sectional view, partly exploded, of another form ofwall base construction;

FIG. 39 is a view similar to FIG. 38 showing the various components inan assembled relation;

FIG. 40 is a fragmentary, vertical sectional view, of still another formof a wall base construction of this invention;

FIG. 41 is a cross sectional view of a modified base clip used inconjunction with the wall base construction of FIG. 40;

FIG. 42 is a cross sectional view of another form of filler block ofthis invention;

FIG. 43 is a cross sectional view of another form of filler block ofthis invention;

FIG. 44 is a view similar to FIG. 40, showing a completed wall baseconstruction;

FIG. 45 is a cross sectional view of an element employed in the wallbase construction of FIG. 44;

FIG. 46 is a cross sectional view of a carpet retaining element used inconjunction with the element of FIG. 45;

FIG. 47 is a cross sectional view of a floor edging member used with thewall base construction of FIG. 44;

FIG. 48 is a vertical sectional view, illustrating still another form ofa wall base construction of this invention;

FIG. 49 is a cross sectional view of a modified base clip used inconjunction with the wall base construction of FIG. 48;

FIG. 50 is a vertical sectional view, taken about on line 50-50 of FIG.1, showing one form of a threshold assembly;

FIG. 51 is a vertical sectional view ofa wall base construction, showinganother form of wall base construction;

FIG. 52 is a vertical sectional view illustrating a modified form ofwall base construction and threshold assembly;

FIG. 53 is a partially cut away and sectional perspective view of thedouble wall construction of this invention, showing a thresholdcomponent prior to assembly with the former;

FIG. 54 is a fragmentary, horizontal sectional view of a door assemblyused in this invention;

FIG. 55 is a partially cut away and fragmentary, sectional perspectiveview of a door frame assembly component, showing a portion of the doorassembly secured thereto;

FIG. 56 is a horizontal sectional view, on an enlarged scale, takenabout on line 56-56 of FIG. 1;

FIG. 57 is a cross sectional view, of a locking member, used inconjunction with the door frame assembly of this invention;

FIG. 58 is a partially cut away and fragmentary, sectional perspectiveview of a header assembly forming a part of the door frame assembly;

FIG. 59 is a fragmentary, vertical sectional view, on an enlarged scale,taken about on line 59-59 of FIG.

FIG. 60 is a vertical sectional view, illustrating portions of the doorframe assembly in a solid wall construction;

FIG. 61 is a vertical sectional view, partly in side elevation, showingthe header and side frame of the door frame assembly just prior toassembly;

FIG. 62 is a horizontal sectional view taken about on line 62-62 of FIG.60;

FIG. 63 is a view similar to FIG. 61, showing the threshold and sideframe of the door frame assembly just prior to assembly;

FIG. 64 is a fragmentary, perspective view of the double wallconstruction of this invention, illustrating a cut out section for theplacement of a window therein;

FIG. 65 is an expanded view of a window frame assembly including awindow unit therefor constructed in accordance with this invention;

FIG. 66 is a fragmentary, perspective sectional view, on an enlargedscale, taken about on lines 66-66 of FIG. 1;

1. Means for supporting a glazing assembly in a wall constructioncomprising: a wall structure provided with a rectangular openingtherethrough defined by vertical and horizontal edges; a window frameassembly comprising a plurality of separably mounted channel shapedmembers arranged and interfitted vertically and horizontally to form anassembled frame for said opening; each of said members comprising a weboverlying one of said edges and spaced, parallel outer legs extending ina direction generally normal to said web in overlapping relation withportions of the exposed surfaces of said wall structure; said web havinga longitudinal recess substantially centrally thereof for supporting aglazing assembly; said recess defining a longitudinal abutment shoulderagainst which one side of said glazing assembly is positioned; said webhaving a longitudinal groove adjacent said recess and a separablelocking member concealing a portion of said channel member and having aprojection snap fitted into said groove and engagable against the otherside of said glazing assembly for securing said glazing assembly inplace.
 2. Means for supporting a glazing assembly in a wall constructioncomprising: a wall structure provided with a rectangular openingtherethrough defined by vertical and horizontal edges; a window frameassembly comprising a plurality of channel shaped members arrangedvertically and horizontally to form a frame for said opening; each ofsaid members comprising a web overlying one of said edges and spaced,parallel outer legs extending in a direction generally normal to saidweb in overlapping relation with portions of the exposed surfaces ofsaid wall structure; said web having a longitudinal recess forsupporting a glazing assembly and a longitudinal groove adjacent saidrecess; and a separable locking member having a projection snap fittedinto said groove for securing said glazing assembly in place; said wallconstruction comprising a pair of spaced panel members and said channelshaped member including an intermediate leg in substantial parallelismwith said outer legs and extending between said opposed panel members.3. Means for supporting a glazing assembly in a wall constructioncomprising: a wall structure provided with a rectangular openingtherethrough defined by vertical and horizontal edges; a window frameassembly comprising a plurality of channel shaped members arrangedvertically and horizontally to form a frame for said opening; each ofsaid members comprising a web overlying one of said edges and spaced,parallel outer legs extending in a direction generally normal to saidweb in overlapping relation with portions of the exposed surfaces ofsaid wall structure; said web having a longitudinal recess forsupporting a glazing assembly and a longitudinal groove adjacent saidrecess; and a separable locking member having a projection snap fittedinto said groove for securing said glazing assembly in place; saidlocking member being provided with right angularly related legs; one ofsaid legs overlying one of said channel member outer legs and the otherlocking member leg overlying a portion of said web and terminating insaid projection.
 4. Supporting means as defined in claim 3 wherein saidone locking member leg is provided with an inturned flange forsnap-fitted engagement behind the edge of said one channel member outerleg.
 5. Supporting means as defined in claim 3 wherein the opposite endsof said one locking member leg project axially beyond said other rightangularly related leg thereof and are provided with inturned segmentsengagable against the edges of said one channel member legs of saidvertically extening channel shaped members.
 6. Means for supporting aglazing assembly in a wall construction comprising: a wall structureprovided with a rectangular opening therethrough defined by vertical andhorizontal edges; a window frame assembly comprising a plurality ofchannel shaped members arranged vertically and horizontally to form aframe for said opening; each of said members comprising a web overlyingone of said edges and spaced, parallel outer legs extending in adirection generally normal to said web in overlapping relation withportions of the exposed surfaces of said wall structure; a glazingasssembly; said web having a longitudinal recess for supporting saidglazing assembly and a longitudinal groove adjacent said recess; aseparable locking member having a projection snap fitted into saidgroove for securing said glazing assembly in place; said glazingassembly comprising a rectangularly shaped primary frame having arecessed offset portion for supporting a glazing panel for defining anabutment bearing shoulder ofr one side of said glazing panel; and asecondary rectangularly shaped frame secured to said offset portion andbearing against the other side of said glazing panel to secure thelatter in place.